Toilet flapper from stainless steel

ABSTRACT

Improvements in a toilet flapper that is formed from an assembly of stainless steel components. The flapper includes hinge pivoting arms, the main body and the float as an integrated assembly. The integrated assembly is made from stamped and formed thin stainless steel sheet metal components that provide sufficient buoyance to allow the flapper to open and close. The toilet flapper made from stainless steel for the float to be sufficiently sized to fit within the throat of the drain pipe and also provide sufficient buoyancy for operation. The toilet flapper made from stainless steel for the flapper to remain flat. The seat remains flat because the stainless steel is essentially not affected by chemicals or age. The stainless steel is preferably 300 series and more preferably 304 stainless, but other types will provide similar sealing and structural functionality.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of Provisional Application Ser. No.61/624,735 filed Apr. 16, 2012 the entire contents of which is herebyexpressly incorporated by reference herein.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT

Not Applicable

INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC

Not Applicable

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to improvements in a flapper for a toilet. Moreparticularly, the present toilet flapper is made from stainless steelthat creates a flapper that will not deteriorate from contamination ofwater and chemicals.

2. Description of Related Art Including Information Disclosed under 37CFR 1.97 and 1.98.

Most toilets utilize a flapper valve that is opened to flush the toilet.When the valve is opened is allows water that is held in a storage tankto enter into the bowl of the toilet and flush material within thetoilet down the drain and into the septic system. Typically the flappervalve is made from a molded plastic material. The water supply into ahouse from the water companies often contains chlorine that deterioratesplastics and rubbers. It is also common to place disinfectants or otherchemicals into the storage tank to clean and disinfect the water such aschlorine, or bleach. While these chemicals clean the water they can havea detrimental effect on a plastic flapper valve. The flapper can deformthereby allowing water to seep around the seal and cause water loss.

A number of patents have been made to address these issues. Exemplaryexamples of patents and or publication that try to address toiletflapper valves problem(s) are identified and discussed below.

Patents or publications that are constructed from an assembly ofcomponents are disclosed in U.S. Pat. No. 3,369,259 that issued on Feb.20, 1968 to R. E. Harold, U.S. Pat. No. 6,173,457 that issued on Jan.16, 2001 to Gary R. Higgins and Published application US 2006/0195977that published on Sep. 7, 2006 to Ching-chen Shieh disclose toilet,flush, drain or flapper valves. These valves are constructed from anumber of plastic and or elastomeric components that are assembled tomake the flapper valve. While they disclose an assembly of componentsthe majority of the components are plastics that can be affected bychemicals that are used to clean toilets and chlorine from major watersupply companies.

U.S. Pat. No. 1,255,090 that issued on Jan. 29, 1918 to R. A. Gaily andU.S. Pat. No. 5,400,444 that issued on Mar. 28, 1995 to Jacques E. Boyerboth disclose valves or flush valves with a metallic element. In thesepatents the metallic element is typically a spring that is not effectedby the toilet chemicals. Neither of these patents discloses the entirebody of the valve being constructed from metal.

Recent flapper valve designs have been made from a single homogeneouselastomeric material. Examples of these designs are found in U.S. Pat.No. 4,499,616 that issued on Feb. 19, 1985 to Dwight N. Johnson, U.S.Pat. No. 5,117,514 that issued on Jun. 2, 1992 to Robert A. Richter,U.S. Pat. No. 5,983,412 that issued on Nov. 16, 1999 to Var E. Lordahland U.S. Pat. No. 7,891,028 that issued on Feb. 22, 2011 to AnthonyCamargo et al. The use of a homogeneous elastomeric material provides acost effective solution making a flapper valve, but while the materialcan shrink, and potato chip from harsh cleaning materials therebyrequiring replacement.

What is needed is a flapper valve that never requires replacement. Themajority of the flapper valve must be made from a material that is notaffected by harsh cleaning chemicals. The proposed flapper valve in thisdocument provides a solution to this problem.

BRIEF SUMMARY OF THE INVENTION

It is an object of the toilet flapper made from stainless steel for theflapper to be entirely made from stainless steel except for areplaceable seal. The flapper includes hinge pivoting arms, the mainbody and the float as an integrated assembly. The integrated assembly ismade from stamped and formed thin stainless steel sheet metal componentsthat provide sufficient buoyance to allow the flapper to open and close.An assembly of two or more components creates the hinge, flapper coverthat provides support for a seal and the float.

It is an object of the toilet flapper made from stainless steel for thefloat to be sufficiently sized to fit within the throat of the drainpipe and also provide sufficient buoyancy for operation. The metalitself is heavier than the surrounding water and the float must besufficiently formed to provide smooth water flow for the flushingprocess. The flow of the water around the float provides the flushingforce to push waste out of the toilet bowel.

It is another object of the toilet flapper made from stainless steel forthe seal to be replaceable. While the body of the float will notdeteriorate from harsh chemicals the seal material can be affected bysome chemicals. The only function of the seal is to prevent water fromflowing through a closed flapper. Over time the seal may take a formedseat around the porcelain of the toilet drain. While the seal mayharden, the shape of the sealing surface will remain essentiallyunchanged whereby minimizing a requirement to change the elastomericseal.

It is still another object of the toilet flapper made from stainlesssteel for the flapper to remain flat. The seat remains flat because thestainless steel is essentially not affected by chemicals or age. Thestainless steel is preferably 300 series and more preferable 304stainless, but other types will provide similar sealing and structuralfunctionality such as but not limited to 316L stainless or titanium.

Various objects, features, aspects, and advantages of the presentinvention will become more apparent from the following detaileddescription of preferred embodiments of the invention, along with theaccompanying drawings in which like numerals represent like components.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

FIG. 1 shows an exploded view of the toilet flapper made from stainlesssteel.

FIG. 2 shows an assembled view of the toilet flapper made from stainlesssteel.

FIG. 3 shows a cross-sectional view of the toilet flapper made fromstainless steel.

FIG. 4 is a bottom perspective view of the toilet flapper made fromstainless steel.

FIG. 5 is a top perspective view of the toilet flapper made fromstainless steel.

FIG. 6 shows an elevation view, shown partially in cross-section of thetoilet flapper made from stainless steel installed within a flushingmechanism in a toilet tank.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows an exploded view of the toilet flapper 10 made fromstainless steel, FIG. 2 shows an assembled view of the toilet flapper 10made from stainless steel, FIG. 3 shows a cross-sectional view of thetoilet flapper made from stainless steel 10, FIG. 4 is a bottomperspective view of the toilet flapper made from stainless steel andFIG. 5 is a top perspective view of the toilet flapper made fromstainless steel.

The flapper 10 is made from essentially entirely made from stainlesssteel except for a replaceable seal 61. The flapper includes hingemember 20 having pivoting arms 27 and 28, the main body 40 and the float50 as an integrated assembly 10. The integrated assembly is preferablymade from stamped and formed 300 series stainless steel and samples havebeen made using 304 stainless, but other types will provide similarsealing and structural functionality including but not limited to 316Lstainless, titanium, brass, copper bronze, aluminum or other materials.Functional units of the stainless steel components have been fabricatedfrom material having a thickness of about 0.015 inches thick. Thisthickness of material is thin enough to provide sufficient buoyance toallow the flapper to open and close. An assembly of two or morecomponents creates the hinge, flapper cover that provides support for aseal and the float.

The hinge member 20 has an essentially flat bottom surface a surroundingraised lip that provides structural strength. The hinge member isinitially stamped from flat material and is bent, stamped, drawn orotherwise formed to create the final shape. Two arms 27 and 28 extendfrom the supporting head section. Dimples or structural bends 23 createadditional strength to the arms and prevent twisting of the arms 27 and28. At the ends of the arms hinge pivot members exist that pivot onpivoting lug(s) 75 as shown in FIGS. 3 and 4. The pivoting members maybe configured to have a formed bearing surface 21 that spreads the pivotsurface over a larger area to reduce premature failure of the pivotinglug(s) 75. The ends of the pivot engagement members 24 may also beslightly bent outward to make connection with the pivoting log(s) 75easier as well and create a different location where the ends might cuta notch in a softer pivoting lug. In addition to the formed bearingsurface the top of the arms 27 and 28 may have an extended formed area22 that provides a broader surface for a user to press on the top of thearms to engage the pivoting portion of the arm(s) onto the pivotinglug(s) 75.

A hole 26 in the front of the hinge member is provided as a connectionmember for a pull chain that opens the flapper valve 10. Hole 25 is alocating hole uses for fabrication of the hinge member 20. A hole 29 inthe center of the head provides a connection for the main body 40. Thehinge member 20 has a flat under surface for mounting the main body 40.

The main body 40 is formed with a number of steps. The lower portion ofthe main body has a lower lip 41. Within the lower lip 41 a gasket orseal 61 is located. The gasket 61 is shown in this embodiment as a flatmember, but it is also contemplated that the gasket 61 can be formedwith a labyrinth seal or be conically shaped to fit within a drainopening. The gasket 61 is fairly compliant and flexible to accommodateangular and surface imperfections in the drain seat. A raised lip 42extends from the gasket seat area. The raised lip 42 provides a sidebearing surface for the float 50. The top 43 of the main body has a hole44 for a connection mechanism to secure the main body to the hingemember. A gasket seal holder 51 provides a seat for locating a float 50.

The float 50 is sufficiently sized to fit within the throat of the drainpipe and also provide sufficient buoyancy for operation. The metalitself is heavier than the surrounding water and the float must besufficiently formed to provide smooth water flow for the flushingprocess. The flow of the water around the float provides the flushingforce to push waste out of the toilet bowel. The internal volume of thefloat is preferably between one and two cubic inches, and morepreferably between 1.4 and 1.8 cubic inches. The variation of theinternal volume is based upon the materials and the open/close cycle ofthe valve.

A fastener 60 secures the hinge member 20 to the main body 40. Thefastening member creates a water tight seal between these twocomponents.

FIG. 6 shows an elevation view, shown partially in cross-section of thetoilet flapper made from stainless steel installed within a flushingmechanism in a toilet tank. The bottom wall 80 of a conventional flushtank supporting a drain outlet housing 81 with an overflow stand pipe 71that is formed in the conventional manner such as molding and includes athrough passageway in the stand pipe 71 for flow to bypass the mainflushing drain 81 by flowing through bypass opening 84. A gasket 82seals the drain pipe 81 with the bottom wall 80 of the toilet tank.

The stand pipe 71 has pivoting lugs on each side of the stand pipe 71for mounting the pivoting arms pivot 21. The upwardly extending portionsof the pivot lugs 75 providing handle means against which the fingers ofthe hand may be pressed using the stand pipe 71 as a fulcrum to move thepivot lugs 75.

The toilet flapper 10 is pivotally mounted on the pivot lugs 75 by apair of pivot legs 27 and 28 which extends from in hinge member 20, mainbody 40 and the float 50. The legs 27 and 28 are spaced in anessentially parallel relation and which are mounted on the outwardlyextending portions of the pivot lugs 75. Each of the pivot legs 27 and28 is sufficiently flexible to permit the extending ends to slightlyflex as they connect onto the pivot lug(s) 75.

The toilet flapper 10 includes an annular cushion 61 joined to theflapper cover 40 that aligns concentrically with respect to theperipheral wall 83 and aligned so as to bear substantially at the inneredge of the bottom wall 83 to form an annular air space for cushioningthe bottom surface of the gasket 61. The bottom surface of the annularcasket 61 presents a substantially annular seating surface for abutmentwith the drain outlet rim 83 when the toilet flapper 10 is in its seatedposition. The seating surface 83 and the peripheral wall areapproximately one half as thick as the top wall so as to be relativelyflexible, and as the level of the stored water begins to rise above thetoilet flapper 10. The gravity head of the water acts downwardly againstthe rigid top wall of the hinge 20 causing the relatively flexiblegasket 61 to deform and create a seal. The gasket 61 acts togetherbottom of the flapper cover and the drain seat 83 to concentrate thegravity head of water at the inner and outer edges creating a seatingsurface.

To initiate a flush the arm 70 is raised thereby lifting chain, or links74 from a slack position 72 to a raised position 73 thereby creating aflush that allows water to flow past the flapper valve 10. Once thewater level within the tank is reduced the flapper valve 10 will dropinto the drain 83 thereby closing the flush valve.

Thus, specific embodiments of a toilet flapper made from stainless steelhave been disclosed. It should be apparent, however, to those skilled inthe art that many more modifications besides those described arepossible without departing from the inventive concepts herein. Theinventive subject matter, therefore, is not to be restricted except inthe spirit of the appended claims.

1. A toilet flapper comprising: an assembly of a hinge, flapper coverand a float; said hinge connects from pivot points on a stand pipe; saidhinge connects to a flapper cover that is sized to accept a seal thatprevents undesirable flow through a toilet flush valve fitting, and afloat that is sized to fit within said toilet flush valve fitting andprovide sufficient buoyancy to operate a flushing cycle.
 2. The toiletflapper according to claim 1 wherein said assembly is made from 300series stainless steel.
 3. The toilet flapper according to claim 2 thatis made from 300 series stainless steel.
 4. The toilet flapper accordingto claim 3 wherein said toilet flapper is more preferably made from 304series stainless steel.
 5. The toilet flapper according to claim 1wherein at least one component from said assembly is constructed fromstamped or drawn plate material.
 6. The toilet flapper according toclaim 1 wherein said seal is replaceable.
 7. The toilet flapperaccording to claim 1 that further includes a seal holder.
 8. The toiletflapper according to claim 7 wherein said seal holder is secured to saidfloat.
 9. The toilet flapper according to claim 8 wherein said sealsecures onto said seal holder.
 10. The toilet flapper according to claim1 wherein said seal is a flat disk.
 11. The toilet flapper according toclaim 1 wherein said seal is a conical ring.
 12. The toilet flapperaccording to claim 1 wherein said float has an internal volume ofbetween 1 and 2 cubic inches. 13 The toilet flapper according to claim12 wherein said internal volume is more preferably between 1.4 and 1.8cubic inches.
 14. The toilet flapper according to claim 1 wherein saidflapper valve is connected to a flush arm with a coupling.
 15. Thetoilet flapper according to claim 14 wherein said coupling is asemi-rigid coupling or a flexible coupling.
 16. The toilet flapperaccording to claim 14 that further includes a hook that connects to aflushing arm.
 17. The toilet flapper according to claim 1 wherein saidassembly is secured with at least two fastener.
 18. The toilet flapperaccording to claim 17 wherein said at least one fastener is a rivet. 19.The toilet flapper according to claim 1 wherein said hinge has formedbearing surface corners.